Cyclone assembly for surface cleaning apparatus and a surface cleaning apparatus having same

ABSTRACT

A cyclone assembly for a surface cleaning apparatus has an openable lower end, a first cyclonic cleaning stage, a second cyclonic cleaning stage, and an airflow passage from the first cyclonic cleaning stage to the second cyclonic cleaning stage. The lower end is moveable to an open position in which at least a portion of the air flow passage is opened.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/137,814, filed on Apr. 25, 2016, which is still pending, thedisclosure of which is incorporated herein by reference in its entirety.

FIELD

This disclosure relates generally to cyclone assemblies for surfacecleaning apparatus, and more specifically to cyclone assemblies thathave first and second cyclonic cleaning stages.

INTRODUCTION

Various types of surface cleaning apparatus are known, including uprightsurface cleaning apparatus, canister surface cleaning apparatus, sticksurface cleaning apparatus, hand carriable surface cleaning apparatus,and central vacuum systems.

Surface cleaning apparatus that use one or more cyclonic cleaning stagesto remove particulate matter (e.g. dust and dirt) from an airstream areknown.

A second cyclonic cleaning stage, which may comprise a plurality ofcyclones in parallel, may be provided downstream of a first cycloniccleaning stage and upstream of the suction motor. The second cycloniccleaning stage is typically provided to remove particulate matter fromthe airstream exiting the first cyclonic cleaning stage and was notremoved from the airstream by the first cyclonic cleaning stage.

Typically, second stage cyclones are effective at removing additionalparticulate matter from the airstream. However, a pre-motor filter isoften provided downstream of the first cyclonic cleaning stage andupstream of the suction motor to protect the suction motor by filteringout particulate matter from the airstream that was not removed from theairstream by either the first or second cyclonic cleaning stage.However, there may be one or more disadvantages associated withproviding a pre-motor filter. For example, the pre-motor filter maybecome clogged with particulate matter, requiring a user to clean and/orreplace the filter, a task a user may regard as undesirable.

SUMMARY

The following introduction is provided to introduce the reader to themore detailed discussion to follow. The introduction is not intended tolimit or define any claimed or as yet unclaimed invention. One or moreinventions may reside in any combination or sub-combination of theelements or process steps disclosed in any part of this documentincluding its claims and figures.

In accordance with one aspect of this disclosure, a cyclone assemblythat may be used as an air treatment member to remove particulate matter(e.g. dirt, dust) from an airflow includes a first cyclonic cleaningstage and a second cyclonic cleaning stage located downstream of thefirst cyclonic cleaning stage wherein the second cyclonic cleaning stageincludes a greater number of cyclone chambers than the first cycloniccleaning stage. The first and second cyclonic stages are configured toprovide reduced back pressure caused by air flow through the cyclonicstages. To this end, the cyclone chambers of the second cycloniccleaning stage may be taller than the cyclone stage(s) of the firstcyclonic cleaning stage.

In order to reduce backpressure through such a cyclone assembly, it ispreferred that the velocity of the airflow entering the first cycloniccleaning stage is approximately equal to the velocity of the airflowentering the second cyclonic cleaning stage. While the airflow velocitythrough the first stage air inlet is preferably approximately equal tothe airflow velocity through each of the second stage air inlets, theseparation characteristics of the first and second cyclonic cleaningstages may nonetheless be different. For example, if a second stagecyclone chamber has a smaller radius than the first stage cyclonechamber, particles entrained in the airflow in the second stage cyclonewill experience a greater centrifugal force than they experienced in thefirst stage cyclone, which may promote the dis-entrainment of smallerparticles from the airflow in the second cyclonic cleaning stage.

In an effort to achieve relatively equal airflow velocities (e.g., ±25%,±20%, ±15%, ±10%, ±5%, the total cross-sectional area of the airinlet(s) of the first cyclonic cleaning stage is preferablyapproximately equal to the total cross-sectional area of the secondstage air inlets (i.e. the sum of the cross-sectional areas of eachsecond stage cyclone chamber air inlet). If the first cyclonic cleaningstage comprises a single cyclone chamber, then the total cross-sectionalarea of the air inlet of the first cyclonic cleaning stage is preferablyapproximately equal to the total cross-sectional area of the secondstage air inlets.

However, due to boundary layer effects at the perimeter, the effectivecross-sectional area of an air inlet may be smaller than the physicaldimensions of the inlet. For example, for a rectangular air inlet ofheight H, width W, and assuming a constant boundary layer thicknessL_(B), the effective cross sectional area for the inlet may be estimatedas:

Area_(Effective)=(H−(2×L _(B)))×(W−(2×L _(B)))=HW−2(HL _(B) +WL _(B)−2L_(B) ²).

If the second cyclonic cleaning stage has a larger number of secondstage cyclones than the first cyclonic cleaning stage, and therefore alarger number of air inlets, and the sum of the cross sectional areas ofthe first stage air inlets is equal to the sum of the cross sectionalareas of the second stage air inlets, then the sum of the effectivecross sectional areas of the first stage air inlets may be less than thesum of the effective cross sectional areas of the second stage airinlets. The reason for this is that the total effective cross-sectionalarea of the second stage air inlets may be reduced by a greater amountthan that of the first stage air inlet(s) as the boundary layerthickness at the perimeter of an inlet is typically not dependent on thearea of the inlet. To adjust for this imbalance, the totalcross-sectional area of the second stage air inlets, and optionally thecross-sectional area of each second stage air inlet, may be increased byabout 5 to 30%, preferably about 10 to 20%, and more preferably by about15% over what would be required to provide an approximately equal totalphysical inlet area for the second stage.

Also, it may be assumed that, generally, during each revolution within acyclone chamber, an air stream moves in the longitudinal directiontowards an end of the cyclone chamber by about the height of the cyclonechamber air inlet. For example, in a cyclone chamber that has alongitudinal height that is five times greater than the longitudinalheight of its air inlet, the air may be expected to rotate about fivetimes as it travels from the end of the cyclone chamber that has the airinlet to the opposite end of the cyclone chamber.

Accordingly, to provide first and second stage cyclones that have aboutthe same number of turns within their respective cyclone chambers, eachcyclone chamber preferably has a similar ratio of the longitudinalheight of its air inlet to the longitudinal height of the cyclonechamber. Thus, where the longitudinal height of the air inlet for eachsecond stage cyclone chamber is greater than the longitudinal height ofthe air inlet for the first stage cyclone chamber, the height of eachsecond stage cyclone chamber is preferably greater than the height ofeach first stage cyclone chamber.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage cyclone having a first stage cyclone chamber, each        first stage cyclone having a first stage longitudinal cyclone        axis about which the air rotates in the first stage cyclone        chamber, each first stage cyclone chamber having a height        extending between a first stage cyclone chamber air inlet and a        first stage cyclone dirt outlet; and    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of second        stage cyclones in parallel, each of the plurality of second        stage cyclones has a second stage cyclone chamber having a        second stage longitudinal cyclone axis about which the air        rotates in the second stage cyclone chamber, each second stage        cyclone chamber having a height extending between a second stage        cyclone chamber air inlet and a second stage cyclone dirt        outlet,    -   wherein the second cyclonic cleaning stage has a larger number        of second stage cyclones than the first cyclonic cleaning stage,        and wherein the height of each second stage cyclone chamber is        greater than the height of each first stage cyclone chamber.

In some embodiments, the second stage cyclone dirt outlets may beprovided in sidewalls of the second stage cyclones.

In some embodiments, the first and second stage longitudinal cycloneaxes may be generally parallel.

In some embodiments, the first and second stage cyclones may beinverted.

In some embodiments, some or all of the second stage cyclone chamber airinlets may have a height in a direction of the second stage longitudinalcyclone axis that is greater than a height of each first stage cyclonechamber air inlet in a direction of the first stage longitudinal cycloneaxis.

In some embodiments, the height of some or all of the second stagecyclone chamber air inlets may be 1.25 to 2.5 times greater than theheight of each first stage cyclone chamber air inlet.

In some embodiments, the height of each second stage cyclone chamber maybe greater than the height of each first stage cyclone chamber by atleast the height of the first stage cyclone chamber air inlet.Optionally, in some embodiments, each of the second stage cyclonechamber air inlets may have a height in a direction of the second stagelongitudinal cyclone axis that is 1.25 to 2.5 times greater than aheight of each first stage cyclone chamber air inlet in a direction ofthe first stage longitudinal cyclone axis.

In some embodiments, each of the second stage cyclone chamber air inletsmay have a width in a direction transverse to the second stagelongitudinal cyclone axis according to the following formula:

${W_{2} = {\frac{W_{1}}{N} \pm {15\%}}},$

wherein W₂ is the width of the second stage cyclone inlets in adirection transverse to the second stage longitudinal cyclone axis; W₁is the width of the first stage cyclone inlets in a direction transverseto the first stage longitudinal cyclone axis; and, N is the number ofsecond stage cyclones. Optionally, in some embodiments, some or all ofthe second stage cyclone chamber air inlets may have a height in adirection of the second stage longitudinal cyclone axis that is greaterthan a height of the first stage cyclone chamber air inlet in adirection of the first stage longitudinal cyclone axis. Optionally, insome embodiments, the height of some or all the second stage cyclonechamber air inlets may be 1.25 to 2.5 times greater than the height ofthe first stage cyclone chamber air inlet.

In some embodiments, each of the first and second stage cyclone chamberair inlets may have a cross sectional area and a total of the crosssectional areas of the second stage cyclone chamber air inlets may begreater than a total of the cross sectional area of the first stagecyclone chamber air inlets.

In some embodiments, the total of the cross sectional areas of thesecond stage cyclone chamber air inlets may be 1.1-2, 1.1-1.5 or 1.1-1.3times greater than the total of the cross sectional area of the firststage cyclone chamber air inlets.

In some embodiments, each of the first and second stage cyclone chamberair inlets has a cross sectional area and a total of the cross sectionalareas of the second stage cyclone chamber air inlets may be greater thana total of the cross sectional area of the first stage cyclone chamberair inlets.

In some embodiments, each of the first and second stage cyclone chambershas a cyclone chamber air outlet and each cyclone chamber air outlet hasa cross sectional area and a total of the cross sectional areas of thesecond stage cyclone chamber air outlets may be greater than a total ofthe cross sectional area of the first stage cyclone chamber air outlets.

In some embodiments, the total of the cross sectional areas of thesecond stage cyclone chamber air outlets may be 1.1-2, 1.1-1.5 or1.1-1.3 times greater than the total of the cross sectional area of thefirst stage cyclone chamber air outlets.

In some embodiments, the height of each first stage cyclone chamber maybe selected such that air rotates 2-4 times in each first stage cyclonechamber and the height of each second stage cyclone chamber may beselected such that air rotates 2-4 times in each second stage cyclonechamber.

In some embodiments, the height of each first and second stage cyclonechamber may be selected such that air rotates about 3 times in eachcyclone chamber.

In accordance with another aspect of this disclosure, at least a portionof, and preferably most or substantially all of a second stage dirtcollection region may be positioned longitudinally above and overlyingthe first stage cyclone chamber. Providing the second stage dirtcollection region in such a location may facilitate a more compactdesign of a two stage cyclone assembly.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage inverted cyclone having a first stage cyclone        chamber and an upper end;    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of inverted        second stage cyclones in parallel, each of the plurality of        second stage cyclones has a second stage cyclone chamber,    -   wherein the second cyclonic cleaning stage comprises a second        stage dirt collection region and at least a portion of the        second stage dirt collection region is positioned longitudinally        above the first stage cyclone chamber and overlying the first        stage cyclone chamber.

In some embodiments, the at least a portion of the second stage dirtcollection region may be positioned on the upper end.

In some embodiments, the second stage dirt collection region may beexternal to the second stage cyclones.

In some embodiments, the second stage dirt collection region maycomprise a plurality of second stage dirt collection chambers.

In some embodiments, each second stage cyclone chamber has a secondstage cyclone dirt outlet, each of which may be provided in a sidewallof one of the second stage cyclones.

In some embodiments, the first cyclonic cleaning stage has a first stagedirt collection region that may be external to the at least one firststage inverted cyclone and each first stage cyclone chamber has a firststage cyclone dirt outlet which may be provided in a sidewall of the atleast one first stage inverted cyclone.

In some embodiments, the cyclone assembly may further comprise anopenable lid which closes an upper end of the second stage cyclones andthe second stage dirt collection region wherein when the openable lid isin an open position, the upper end of the second stage cyclones and thesecond stage dirt collection region may be opened.

In some embodiments, the first cyclonic cleaning stage has a first stagedirt collection region that may be external to the at least one firststage inverted cyclone and the cyclone bin assembly has an upper endcomprising the second stage dirt collection region and the upper end maybe moveably to an open position in which the at least one first stageinverted cyclone and the first stage dirt collection region are open.

In some embodiments, when the upper end is in the open position thesecond stage dirt collection region may be closed.

In some embodiments, when the upper end is in the open position thesecond stage cyclones may also be opened.

In some embodiments, the cyclone assembly further comprises an openablelid which may close an upper end of the second stage dirt collectionregion wherein when the openable lid is in an open position, the upperend of the second stage dirt collection region may be opened and theopenable lid may be openable when the upper end is in the open position.

In some embodiments, when the upper end comprises an upper openable lidwhich closes an upper end of the second stage dirt collection region anda lower wall, the lower wall may comprise an upper end wall of the atleast one first stage inverted cyclone.

In accordance with another aspect of this disclosure, an upstreampre-motor filter chamber or manifold may be positioned facing, e.g.,below, the second cyclonic cleaning stage and each of the second stagecyclone air outlets may have an outlet extend to an opening in a wall ofthe chamber or manifold. An advantage of this design is that fewerconduit walls and/or ducting may be required to direct airflow from thesecond cyclonic cleaning stage towards the pre-motor filter, which maysimplify the design and/or construction of the cyclone assembly and/orsurface cleaning apparatus, and/or may reduce backpressure through thesurface cleaning apparatus.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage cyclone, which may be an inverted cyclone, having a        first stage cyclone chamber and a first stage cyclone air        outlet;    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of second        stage cyclones in parallel, each of the plurality of second        stage cyclones may be an inverted cyclone and may each have a        second stage cyclone chamber, each of the second stage cyclones        having a second stage cyclone air outlet; and    -   (c) a pre-motor filter chamber, which may be positioned below        the second cyclonic cleaning stage, wherein each of the second        stage cyclone air outlets has an outlet end in a wall forming an        upstream pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning stage may be removablefrom the pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning may have an openablebottom wall wherein the second stage cyclones are opened when theopenable bottom wall is in an open position.

In some embodiments, the first cyclonic cleaning stage may have a firststage dirt collection region that is external to the at least one firststage inverted cyclone and the first stage dirt collection region may beopened when the openable bottom wall is in an open position.

In some embodiments, the second cyclonic cleaning stage may comprise asecond stage dirt collection region and the cyclone assembly may furthercomprise an openable lid which closes an upper end of the second stagedirt collection region wherein when the openable lid is in an openposition, the upper end of the second stage dirt collection region maybe opened.

In some embodiments, the cyclone assembly may further comprise a headerdownstream of the first stage cyclone air outlet and upstream of thesecond stage cyclones wherein the header is positioned between the firstthe first stage cyclone air outlet and the pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning may have an openablebottom wall wherein the second stage cyclones and the header are openedwhen the openable bottom wall is in an open position.

In some embodiments, the first cyclonic cleaning stage may have a firststage dirt collection region that is external to the at least one firststage inverted cyclone and the first stage dirt collection region may beopened when the openable bottom wall is in an open position.

In accordance with another aspect of this disclosure, a releasemechanism may be provided which is moveable to two open positionswherein, in a first open position, a first lock is moved to an unlockedposition and in a second open position, a second lock is moved to anunlocked position. An advantage of this design is that the same actuatormay be used to unlock an upper end of a cyclone assembly that houses asecond stage dirt collection area and to open an upper lid that opensthe second stage dirt collection area.

In accordance with another aspect of this disclosure, a cyclone assemblymay have an openable lower end, and when the openable lower end is in anopen position at least a portion of an airflow passage between a firstcyclonic cleaning stage and a second cyclonic cleaning stage is opened.An advantage of this design is that opening the lower end may provideaccess to the airflow passage e.g. for cleaning, and/or such aconfiguration may simplify the design and/or construction of the cycloneassembly and/or surface cleaning apparatus.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

(a) an openable lower end;

(b) a first cyclonic cleaning stage comprising at least one first stageinverted cyclone having a first stage cyclone chamber and an upper end;

(c) a second cyclonic cleaning stage downstream from the first cycloniccleaning stage and comprising a plurality of inverted second stagecyclones in parallel, each of the plurality of second stage cycloneshaving a second stage cyclone chamber; and,

(d) an air flow passage from the first cyclonic cleaning stage to thesecond cyclonic cleaning stage,

-   -   wherein the lower end is moveable between a closed position and        an open position in which at least a portion of the air flow        passage is opened.

In some embodiments, the second cyclonic cleaning stage may comprise atleast one second stage dirt collection region that is exterior to thesecond stage cyclone chambers and the at least one second stage dirtcollection region is opened when the lower end is moved to the openposition.

In some embodiments, the lower end may comprise a single pivotallyopenable panel.

In some embodiments, the lower end may comprise at least one outlet portfor the second cyclonic cleaning stage.

In some embodiments, the cyclone assembly may further comprise an upperend that is moveable between a closed position and an opening positionin which the first and second cyclone chambers are opened.

In some embodiments, the cyclone assembly may further comprise a firststage dirt collection region exterior to the first stage cyclone chamberand the first stage dirt collection region is opened when the an upperend is moved to the open position.

In some embodiments, the second cyclonic cleaning stage may comprise atleast one second stage dirt collection region that is exterior to thesecond stage cyclone chambers and the at least one second stage dirtcollection region is opened when the upper end is moved to the openposition.

In accordance with another aspect of this disclosure, a cyclone assemblymay have an openable upper end and an openable lower end, and when theopenable upper end is in an open position, the cyclone chambers of thefirst and second cyclonic cleaning stages are opened, and when theopenable lower end is in an open position, a dirt collection region forthe first cyclonic cleaning stage and at least one dirt collectionregion for the second cyclonic cleaning stage are opened. An advantageof this design is that opening the upper end may provide access to eachcyclone chamber and optionally one or more dirt collection regions e.g.for cleaning, and opening the lower end may provide access to one ormore dirt collection regions for the first and/or second cycloniccleaning stages, and/or such a configuration may simplify the designand/or construction of the cyclone assembly and/or surface cleaningapparatus.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

(a) an openable upper end and an openable lower end;

(b) a first cyclonic cleaning stage comprising at least one first stageinverted cyclone having a first stage cyclone chamber, an upper end anda dirt outlet at the upper end in communication with a first stage dirtcollection region exterior to the first stage cyclone chamber;

(c) a second cyclonic cleaning stage downstream from the first cycloniccleaning stage and comprising a plurality of inverted second stagecyclones in parallel, each of the plurality of second stage cycloneshaving a second stage cyclone chamber, an upper end and a dirt outlet atthe upper end wherein the dirt outlets of the second stage cyclonechambers are in communication with at least one second stage dirtcollection region exterior to the second stage cyclone chambers;

wherein the upper end is moveable between a closed position and anopening position in which the first and second cyclone chambers areopened, and

wherein the lower end is moveable between a closed position and an openposition in which the first stage dirt collection region and the atleast one second stage dirt collection region are opened.

In some embodiments, the second stage may comprise a plurality of secondstage dirt collection regions and the plurality of second stage dirtcollection regions are opened when the lower end is opened.

In some embodiments, the at least one second stage dirt collectionregion may be opened when the upper end is opened.

In some embodiments, the second stage may comprise a plurality of secondstage dirt collection regions and the plurality of second stage dirtcollection regions are opened when the upper end is opened.

In some embodiments, the cyclone assembly may further comprise an airflow passage from the first cyclonic cleaning stage to the secondcyclonic cleaning stage, wherein at least a portion of the air flowpassage is opened when the lower end is opened.

In some embodiments, the lower end may comprise at least one outlet portfor the second cyclonic cleaning stage.

In accordance with another aspect of this disclosure, a cyclone assemblymay have an openable upper end and an openable lower end, and when theopenable upper end is in an open position, the cyclone chambers for thefirst and second cyclonic cleaning stages are opened and optionally oneor more dirt collection regions, and when the openable upper end is in aclosed position it may abut an upper end of sidewalls of the first andsecond cyclonic cleaning stages. An advantage of this design is thatopening the upper end may provide access to each cyclone chamber e.g.for cleaning, and/or such a configuration may simplify the design and/orconstruction of the cyclone assembly and/or surface cleaning apparatus.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

(a) an openable upper end and an openable lower end;

(b) a first cyclonic cleaning stage comprising at least one first stageinverted cyclone having an air inlet and an air outlet at a lower end ofa first stage cyclone chamber and a first stage dirt outlet provided inan upper portion of a first stage cyclone sidewall of the first stagecyclone chamber, the first stage dirt outlet in communication with afirst stage dirt collection region exterior to the first stage cyclonechamber wherein the upper end abuts an upper end of the first stagecyclone sidewall when the upper end is in a closed position;

(c) a second cyclonic cleaning stage downstream from the first cycloniccleaning stage and comprising a plurality of inverted second stagecyclones in parallel, each of the plurality of second stage cycloneshaving a cyclone chamber having an air inlet and an air outlet at alower end thereof and a second stage dirt outlet provided in an upperportion of a second stage cyclone sidewall of the second stage cyclonechamber, wherein the second stage dirt outlets are in communication withat least one second stage dirt collection region exterior to the secondstage cyclone chambers wherein the upper end abuts an upper end of thesecond stage cyclone sidewalls when the upper end is in a closedposition,

wherein, when the upper end is in an open position, the first and secondstage cyclone chambers are opened.

In some embodiments, the second stage may comprise a plurality of secondstage dirt collection regions and the plurality of second stage dirtcollection regions are opened when the lower end is opened.

In some embodiments, the lower end may comprise at least one outlet portfor the second cyclonic cleaning stage.

In some embodiments, the at least one second stage dirt collectionregion may be opened when upper end is opened.

In some embodiments, the second stage may comprise a plurality of secondstage dirt collection regions and the plurality of second stage dirtcollection regions are opened when upper end is opened.

In some embodiments, the cyclone assembly may further comprise an airflow passage from the first cyclonic cleaning stage to the secondcyclonic cleaning stage, wherein at least a portion of the air flowpassage is opened when the lower end is opened.

In some embodiments, the lower end may comprise at least one outlet portfor the second cyclonic cleaning stage.

A pre-motor filter is typically provided downstream of the cycloniccleaning stages and upstream of the suction motor, to preventparticulate matter that is not removed from the airstream by thecyclonic cleaning stages from being drawn into the suction motor.Otherwise, this unremoved particulate matter may cause damage to (orotherwise impair) the suction motor. While the use of a pre-motor filtermay be effective at protecting the suction motor, there may be one ormore disadvantages. For example, the pre-motor filter may become cloggedwith particulate matter, requiring a user to clean and/or replace thefilter, a task a user may regard as undesirable.

In some embodiments disclosed herein, all or substantially all of thedirt entrained in the air exiting the first cyclonic cleaning stage maybe removed from the airflow by the second cyclonic cleaning stage. Thismay, for example, obviate the need to provide a pre-motor filter in thesurface cleaning apparatus.

It will be appreciated by a person skilled in the art that an apparatusor method disclosed herein may embody any one or more of the featurescontained herein and that the features may be used in any particularcombination or sub-combination.

These and other aspects and features of various embodiments will bedescribed in greater detail below.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a better understanding of the described embodiments and to show moreclearly how they may be carried into effect, reference will now be made,by way of example, to the accompanying drawings in which:

FIG. 1 is a perspective view of a surface cleaning apparatus comprisinga cyclone assembly in accordance with one embodiment;

FIG. 2 is a perspective view of the cyclone assembly of FIG. 1;

FIG. 3 is a top perspective view of the cyclone assembly of FIG. 2;

FIG. 4 is a top perspective view of the cyclone assembly of FIG. 2, withan upper lid in an open position;

FIG. 5 is a top perspective view of the cyclone assembly of FIG. 2, withan upper end in an open position and the upper lid in a closed position;

FIG. 6 is a perspective view of the cyclone assembly of FIG. 5, withportions of the outer wall removed for clarity;

FIG. 7 is a bottom perspective view of the cyclone assembly of FIG. 2;

FIG. 8 is a bottom perspective view of the cyclone assembly of FIG. 2,with a bottom in an open position;

FIG. 9 is a cross-section view of the surface cleaning apparatus of FIG.1;

FIG. 10 is an enlarged view of the lower portion of FIG. 9;

FIG. 11 is a section view of the cyclone assembly and suction motorhousing of the surface cleaning apparatus of FIG. 8, taken along line11-11 shown in FIG. 1;

FIG. 12 is a cross-section view of the cyclone assembly of FIG. 2, takenalong line 12-12 shown in FIG. 2;

FIG. 13 is a section view of the cyclone assembly of FIG. 2, taken alongline 13-13 shown in FIG. 2;

FIG. 14 is a cross-section view of the cyclone assembly of FIG. 2, takenalong line 14-14 shown in FIG. 3, with a portion of the lower wall ofthe first stage cyclone removed to reveal a plurality of second stagecyclone chamber air inlets;

FIG. 15 is a top view of the bottom of the cyclone assembly of FIG. 2;

FIG. 16 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 16-16 shown in FIG. 1, with a release mechanismin a neutral position;

FIG. 17 is a top view of the enlarged portion of FIG. 16;

FIG. 18 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 16-16 shown in FIG. 1, with the releasemechanism in a first unlocked position;

FIG. 19 is a cross-section view of the surface cleaning apparatus ofFIG. 1, with the release mechanism in a first unlocked position;

FIG. 20 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 20-20 shown in FIG. 1, with the releasemechanism in a second unlocked position;

FIG. 21 is a top view of the enlarged portion of FIG. 20, with therelease mechanism in a neutral position;

FIG. 22 is a cross-section view of the surface cleaning apparatus ofFIG. 1, with the release mechanism in the second unlocked position;

FIG. 23 is a perspective view of a cyclone assembly in accordance withanother embodiment;

FIG. 24 is a rear perspective view of the cyclone assembly of FIG. 23;

FIG. 25 is a perspective view of the cyclone assembly of FIG. 23, withan upper end in an open position;

FIG. 26 is a top view of the cyclone assembly of FIG. 23, with an upperend in an open position;

FIG. 27 is a bottom perspective view of the cyclone assembly of FIG. 23;

FIG. 28 is a bottom perspective view of the cyclone assembly of FIG. 23,with a lower end in an open position; and,

FIG. 29 is a bottom view of the cyclone assembly of FIG. 23, with alower end in an open position.

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Various apparatuses, methods and compositions are described below toprovide an example of an embodiment of each claimed invention. Noembodiment described below limits any claimed invention and any claimedinvention may cover apparatuses and methods that differ from thosedescribed below. The claimed inventions are not limited to apparatuses,methods and compositions having all of the features of any oneapparatus, method or composition described below or to features commonto multiple or all of the apparatuses, methods or compositions describedbelow. It is possible that an apparatus, method or composition describedbelow is not an embodiment of any claimed invention. Any inventiondisclosed in an apparatus, method or composition described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicant(s), inventor(s) and/or owner(s) do not intend to abandon,disclaim, or dedicate to the public any such invention by its disclosurein this document.

Furthermore, it will be appreciated that for simplicity and clarity ofillustration, where considered appropriate, reference numerals may berepeated among the figures to indicate corresponding or analogouselements. In addition, numerous specific details are set forth in orderto provide a thorough understanding of the example embodiments describedherein. However, it will be understood by those of ordinary skill in theart that the example embodiments described herein may be practicedwithout these specific details. In other instances, well-known methods,procedures, and components have not been described in detail so as notto obscure the example embodiments described herein. Also, thedescription is not to be considered as limiting the scope of the exampleembodiments described herein.

In the examples discussed herein, the surface cleaning apparatus withwhich the cyclone assembly is used is an upright vacuum cleaner. Inalternative embodiments, the surface cleaning apparatus may be anothersuitable type of surface cleaning apparatus, such as a canister typevacuum cleaner, a hand vacuum cleaner, a stick vac, a wet-dry typevacuum cleaner, a carpet extractor, and the like.

General Description of a Surface Cleaning Apparatus

Referring to FIG. 1, a surface cleaning apparatus is shown generally as10. The surface cleaning apparatus includes a surface cleaning head 12and an upper portion 14 that is movably and drivingly connected to thesurface cleaning head 12. The surface cleaning head 12 may be supportedby any suitable support members, such as, for example wheels and/orrollers, to allow the surface cleaning head to be moved across a flooror other surface being cleaned. The support members (e.g., wheels) maybe of any suitable configuration, and may be attached to any suitablepart of the surface cleaning apparatus, including, for example, thesurface cleaning head and/or the upper portion.

The surface cleaning apparatus 10 includes a dirty air inlet 16, a cleanair outlet 18 and an air flow path or passage extending therebetween(See FIGS. 9-11). In the illustrated example, the air flow path includesat least one flexible air flow conduit member (such as a hose 15 orother flexible conduit). Alternatively, the air flow path may be formedfrom rigid members. A cyclone assembly 100 and at least one suctionmotor are provided in the air flow path. Preferably, the cycloneassembly is provided upstream from a suction unit 20 that contains thesuction motor(s), but alternatively may be provided downstream from thesuction motor(s). In addition to the cyclone assembly, the surfacecleaning apparatus may also include one or more pre-motor filters(preferably positioned in the air flow path between the cyclone assemblyand the suction motor) and/or one or more post-motor filters (positionedin the air flow path between the suction motor and the clean airoutlet).

General Description of a Cyclone Assembly

FIGS. 2-8 and 12-15 illustrate an embodiment of a cyclone assembly,referred to generally as 100. Cyclone assembly 100 may be used as an airtreatment member to remove particulate matter (e.g. dirt, dust) from anair flow. Preferably, the cyclone assembly is removable from the surfacecleaning apparatus. Providing a detachable cyclone assembly 100 mayallow a user to carry the cyclone assembly 100 to a garbage can foremptying, without needing to carry or move the rest of the surfacecleaning apparatus 10. Preferably, the cyclone assembly is removable asa closed module, which may help prevent dirt and debris from spillingout of the cyclone assembly 100 during transport.

As shown in FIG. 2, the cyclone assembly 100 has a lower end 102, anupper end 104, and an outer sidewall 108. Preferably, an assembly handle106 is provided at the upper end 104. The assembly handle 106 mayfacilitate carrying of the cyclone assembly when it is detached from thesurface cleaning apparatus 10.

Referring to FIGS. 4-8 and 12-15, cyclone assembly 100 includes a firstcyclonic cleaning stage and a second cyclonic cleaning stage locateddownstream of the first cyclonic cleaning stage. The first cycloniccleaning stage includes a first stage cyclone chamber 110 that extendsalong a cyclone axis 115 and includes a generally cylindrical sidewall111 extending between a lower end wall 113 and an intermediate wall 140(which is an upper end wall of the cyclone chamber 110). In theillustrated embodiment, the first stage cyclone chamber 110 is arrangedin a generally vertical, inverted cyclone orientation. Alternatively,the first stage cyclone chamber can be provided in another orientation,for example as a horizontal or inclined cyclone and may be of anycyclone construction. Alternately, or in addition, the first cycloniccleaning stage may comprise a plurality of cyclone chambers.

In the illustrated embodiment, the first stage cyclone chamber 110includes a first stage cyclone air inlet 112 and a first stage cycloneair outlet 114. First stage cyclone chamber 110 also includes at leastone dirt outlet 118, through which dirt and debris that is separatedfrom the air flow can exit the cyclone chamber 110. While it ispreferred that most or all of the dirt exit the first stage cyclonechamber via the dirt outlet 118, some dirt may settle on the bottom endwall 113 of the cyclone chamber 110 and/or may be entrained in the airexiting the first stage cyclone chamber via the air outlet 114.

In the illustrated example, the first stage cyclone dirt outlet 118 isin the form of a slot bounded by the cyclone side wall 111 and the uppercyclone end wall 140, and is located toward the upper end of the cyclonechamber 110. Alternatively, the dirt outlet may be of any other suitableconfiguration, and may be provided at another location in the cyclonechamber, including, for example as an annular gap between the sidewalland an end wall of the cyclone chamber or an arrestor plate or othersuitable member.

Preferably, the first stage cyclone air inlet 112 is located toward oneend of the cyclone chamber 110 (the lower end in the illustratedexample) and may be positioned adjacent the corresponding cyclonechamber end wall 113. Alternatively, the cyclone air inlet 112 may beprovided at another location within the first stage cyclone chamber 110.Preferably, the air inlet 112 is positioned so that air flowing throughthe inlet and into the first stage cyclone chamber is travellinggenerally tangentially relative to, and preferably adjacent, thesidewall 111 of the cyclone chamber 110.

The cross-sectional shape of the air inlet 112 can be any suitableshape. In the illustrated example of FIG. 12, the air inlet has across-sectional shape that is generally rectangular (e.g., it hasrounded corners and can be referred to as a rounded rectangle) having aheight H_(I) ₁ in the longitudinal direction (i.e. parallel to cycloneaxis 115) and a width W_(I) ₁ in a transverse direction cyclone axis115. The cross-sectional area of the air inlet 112 can be referred to asthe cross-sectional area or flow area of the first stage cyclone airinlet 112. Alternatively, instead of being a rounded rectangle, thecross-sectional shape of the air inlet may be another shape, including,for example, round, oval, square and rectangular.

Referring to FIG. 12, the first stage cyclone chamber 110 has a heightH_(C) ₁ in the longitudinal direction (i.e. parallel to cyclone axis115). The height of the first stage cyclone chamber 110 is preferablyselected such that air entering the cyclone chamber via inlet 112 isexpected to rotate approximately 3 to 6 times, 3 to 5 times, 2 to 4times or three-and-a-half times in the first stage cyclone chamber priorto exiting the cyclone chamber via outlet 114.

In general, it may be assumed that the airflow against the cyclonechamber sidewall as it progresses around the cyclone chamber maintains adegree of cohesion, and that during each revolution within a cyclonechamber, an air stream moves in the longitudinal direction towards anend of the cyclone chamber by a distance approximately equal to theheight of the cyclone chamber air inlet. For example, in a cyclonechamber that has a longitudinal height that is five times greater thanthe longitudinal height of its air inlet, the resulting cyclone may beexpected to rotate about five times as it travels from the end of thecyclone chamber that has the air inlet to the opposite end of thecyclone chamber.

Thus, in order to promote the formation of a cyclone that is expected torotate about three-and-a-half times in the first stage cyclone chamber110, the height H_(C) ₁ of the first stage cyclone chamber 110 may bebetween 3 and 4 times, the height H_(I) ₁ of the first stage cyclone airinlet 112.

Air can exit the first stage cyclone chamber 110 via the first stage airoutlet 114. Preferably, the cyclone air outlet is positioned in one ofthe cyclone chamber end walls and, in the example illustrated, ispositioned in the same end as the air inlet 112 and air inlet 112 may bepositioned adjacent or at the end wall 113. In the illustratedembodiment the air outlet 114 is generally circular in cross-sectionalshape. Preferably, the cross-sectional or flow area of the first stagecyclone air outlet 114 is generally equal to the flow area of the firststage cyclone air inlet 112. In the illustrated example, the cyclone airoutlet 114 comprises a vortex finder 116.

Air exiting the first stage air outlet 114 may be directed into achamber or manifold 117. From there, the air is directed into the secondcyclonic cleaning stage. The second cyclonic cleaning stage includes aplurality of second stage cyclone chambers 120 arranged in parallel. Inthe illustrated embodiment, six second stage cyclone chambers are shown,referred to as 120 a, 120 b, 120 c, 120 d, 120 e, and 120 f,respectively.

In the illustrated embodiment, each second stage cyclone chamber 120 isarranged in a generally vertical, inverted cyclone orientation.Alternatively, the second stage cyclone chambers can be provided inanother orientation, for example as horizontal or inclined cyclones andmay be of any cyclone construction.

In the illustrated embodiment, each second stage cyclone chamber extendsalong a respective cyclone axis 125 (see e.g. FIGS. 5 and 13) andextends between a lower end wall or bottom 130 and an upper end wall150. In the illustrated embodiment, each second stage cyclone chamber isbounded by a lower sidewall 121 and an upper sidewall extension 141.

In the illustrated embodiment, each second stage cyclone chamber 120includes a second stage cyclone air inlet 122 and a second stage cycloneair outlet 124. Each second stage cyclone chamber 120 also includes atleast one dirt outlet 128, through which dirt and debris that isseparated from the air flow can exit the cyclone chamber 120. While itis preferred that most or all of the dirt entrained in the air exitingthe first cyclonic cleaning stage exits the second stage cyclonechambers via the dirt outlets 128, some dirt may settle on the bottomend wall 130 of the cyclone chambers 120 and/or may be entrained in theair exiting the second stage cyclone chambers via the air outlets 124.

In some embodiments, all or substantially all of the dirt entrained inthe air exiting the first cyclonic cleaning stage may be removed fromthe airflow by the second cyclonic cleaning stage. This may, forexample, obviate the need to provide a pre-motor filter in the surfacecleaning apparatus 10.

In the illustrated example, each second stage cyclone dirt outlet 128 isin the form of a slot bounded by the cyclone side wall 121 and the uppercyclone end wall 150, and is located toward the upper end of the cyclonechamber 120. Alternatively, the dirt outlet may be of any other suitableconfiguration, and may be provided at another location in the cyclonechamber, including, for example as an annular gap between the sidewalland an end wall of the cyclone chamber or an arrestor plate or othersuitable member.

Preferably, each second stage cyclone air inlet 122 is located towardone end of the cyclone chamber 120 (the lower end in the illustratedexample) and may be positioned adjacent the corresponding cyclonechamber end wall 130. Alternatively, the cyclone air inlet 122 may beprovided at another location within the second stage cyclone chamber120. Preferably, each air inlet 122 is positioned so that air flowingthrough the inlet and into a second stage cyclone chamber is travellinggenerally tangentially relative to, and preferably adjacent, thesidewall 121 of the cyclone chamber 120.

The cross-sectional shape of the air inlet 122 can be any suitableshape. In the illustrated example each air inlet has a cross-sectionalshape that is generally rectangular (rounded rectangular), having aheight H_(I) ₂ in the longitudinal direction (i.e. parallel to cycloneaxis 125) and a width W_(I) ₂ in a transverse direction. The totalcross-sectional area of the second stage air inlets (i.e. the sum of thecross-sectional areas of each inlet 122 a-f) can be referred to as thetotal cross-sectional area or total flow area of the second cycloniccleaning stage.

Referring to FIG. 12, each second stage cyclone chamber 120 has a heightH_(C) ₂ in the longitudinal direction (i.e. parallel to cyclone axis125). The height of each second stage cyclone chamber 120 is preferablyselected such that air entering the cyclone chambers via inlets 122 isexpected to rotate approximately 3 to 6 times, 3 to 5 times, 2 to 4times or three-and-a-half times in each second stage cyclone chamberprior to exiting the cyclone chamber via outlet 124. For example, theheight H_(C) ₂ of a second stage cyclone chamber 120 may be between 3and 4 times, the height H_(I) ₂ of a second stage cyclone air inlet 122.

Air can exit each second stage cyclone chambers 120 via a second stageair outlet 124 provided for each cyclone chamber 120. Preferably, thecyclone air outlets 124 a-f are positioned in one of the end walls ofeach cyclone chamber 120 and, in the example illustrated, are positionedin the same ends as the air inlets 122 a-f. In the illustratedembodiment the air outlets 124 a-f are generally circular incross-sectional shape. Preferably, the cross-sectional or flow area ofeach second stage cyclone air outlet 124 is generally equal to the flowarea of the first stage cyclone air inlet 112 for its respective cyclonechamber. In the illustrated example, each cyclone air outlet 124comprises a vortex finder 126.

Height of Each Second Stage Cyclone Chamber Greater than the Height ofeach First Stage Cyclone Chamber

The following is a description of the sizing of a second stage cyclonecompared to a first stage cyclone that may be used by itself in anysurface cleaning apparatus or in any combination or sub-combination withany other feature or features disclosed herein including the positioningof the dirt collection region for second stage cyclones, a dual openinglatching mechanism and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In order to reduce backpressure through the cyclone assembly 100, it ispreferred that the velocity of the airflow entering the first cycloniccleaning stage is approximately equal to the velocity of the airflowentering the second cyclonic cleaning stage. That is, the airflowvelocity through the first stage cyclone air inlet 112 may beapproximately equal to the airflow velocity through each of the secondstage cyclone air inlets 122.

In an effort to achieve relatively equal airflow velocities, cycloneassembly 100 may be dimensioned so that the total cross-sectional areaof the air inlet for the first cyclonic cleaning stage (i.e. thecross-sectional area of the air inlet 112 in the illustrated example) isapproximately equal to the total cross-sectional area of the secondstage air inlets (i.e. the sum of the cross-sectional areas of eachinlet 122 a-f).

However, due to boundary layer effects at the perimeter of the inlet,the effective cross-sectional area of each air inlet 112, 122 may besmaller than the physical dimensions of the inlet. For example, aboundary layer having a thickness of about 0.005 to 0.010 inches mayform around the perimeter of each air inlet, reducing the effectivecross-sectional or flow area of that inlet. For example, for arectangular air inlet of height H, width W, and assuming a constantboundary layer L_(B), the effective cross sectional area for the inletmay be estimated as:

Area_(Effective)=(H−(2×L _(B)))×(W−(2×L _(B)))=HW−2(HL _(B) +WL _(B)−2L_(B) ²).

Where the second cyclonic cleaning stage has a larger number of secondstage cyclones than the first cyclonic cleaning stage, as in theillustrated example, the total effective cross-sectional area of thesecond stage air inlets 122 may be reduced by a greater amount than thatof the first stage air inlet 112 (as the boundary layer thickness at theperimeter of an inlet is typically not dependent on the area of theinlet). To adjust for this imbalance, the cross-sectional area of eachsecond stage air inlet 122 is preferably increased by about 10 to 30%,and more preferably by about 15% over what would be required to providean approximately equal physical inlet area to air inlet 112. This may beachieved by varying the width and/or height of the second stage airinlets and preferably varying at least the height of the second stageair inlets. For example, the height of the second stage air inlets maybe increased by about 10 to 30%, and more preferably by about 15%.

While the airflow velocity through the first stage cyclone air inlet 112is preferably approximately equal to the airflow velocity through eachof the second stage cyclone air inlets 122, the separationcharacteristics of the first and second cyclonic cleaning stages maynonetheless be different. For example, since the second stage cyclonechambers 120 each have a smaller radius than the first stage cyclonechamber 110, particles entrained in the airflow in the second stagecyclones will experience a greater centrifugal force than theyexperienced in the first stage cyclone, which may promote thedis-entrainment of smaller particles from the airflow in the secondcyclonic cleaning stage.

In accordance with one feature, the height of each second stage cyclonechamber may be greater than the height of the first stage cyclonechamber. An example of such an arrangement is shown in FIGS. 4-6 and9-13.

Since the second stage cyclone chambers 120 each have a smaller radiusthan the radius of the first stage cyclone chamber 110, and since thewidth of an air inlet to a cyclone chamber is preferably a function ofthe cyclone chamber diameter, each second stage cyclone air inlet 122preferably has a narrower width than that of the first stage inlet 112.For example, an air stream entering a cyclone chamber may more or lessmaintain the same width as it travels through the cyclone chamber.Therefore, the radius of a cyclone chamber may be determined based onthe width of the air stream (the width of the air inlet) and the widthrequired for the return air steam travelling to the cyclone chamber airoutlet (e.g., the width of a vortex finder). Therefore the radius of acyclone chamber may be approximately equal to the width of the cyclonechamber air inlet, the width of the wall of the vortex finder and halfthe diameter of the vortex finder.

In certain preferred embodiments, without taking into account thedecreased flow area due to boundary layer effects, the width W_(I) ₂ foreach inlet 122 a-f may be within about +/−15% of the width W_(I) ₁ forinlet 112 divided by the number of second stage cyclone chambers. Forexample, in the illustrated embodiment, there are six second stagecyclone chambers 120 a-f, so the width W_(I) ₂ for each inlet 122 a-f ispreferably about

$\frac{W_{I_{1}}}{6} \pm {15{\%.}}$

As discussed above, the total cross-sectional area of the second stageair inlets (e.g. the sum of the cross-sectional areas of each inlet 122a-f) may be about 10-30% greater than the total cross-sectional area ofthe first cyclonic cleaning stage (e.g. the cross-sectional area of theair inlet 112), so that the effective flow area of the second cycloniccleaning stage is approximately equal to the effective flow area of thefirst cyclonic cleaning stage, after taking boundary layer effects atthe air inlets into account.

In order to determine the height H_(I) ₂ for each inlet 122, the radiusof the second stage cyclones may be first determined based on, e.g., thecentrifugal forces to be imposed on an air stream travelling therein.The width of the cyclone chamber air inlet 122 may then be determined tobe approximately equal to the radial thickness available in the cyclonechamber in which the air stream will rotate. Finally, the height H_(I) ₂for each inlet 122 may be determined based on the cross sectional arearequired to provide a cross-sectional flow area (taking into accountboundary layer losses) that is approximately equal to thecross-sectional flow area of the first stage cyclone air inlet (takinginto account boundary layer losses).

In certain other preferred embodiments, the height H_(I) ₂ of eachsecond stage cyclone chamber air inlet 122 is between about 1.25 to 2.5,1.25 to 2, 1.25 to 1.75 times greater than the height H_(I) ₁ of theinlet 112.

As noted above, the height H_(C) ₂ of a second stage cyclone chamber 120is preferably between 3 to 6, 3 to 5, 3 to 4 and may be about 3.5 timesthe height H_(I) ₂ of a second stage cyclone air inlet 122, and theheight H_(C) ₁ of the first stage cyclone chamber 110 is preferablybetween 3 to 6, 3 to 5, 3 to 4 and may be about 3.5 times the heightH_(I) ₁ of the first stage cyclone air inlet 112. Thus, since the heightH_(I) ₂ for each inlet 122 is preferably greater than H_(I) ₁ , theheight H_(C) ₁ of each second stage cyclone chamber 120 is preferablygreater than the height H_(C) ₁ of the first stage cyclone chamber 110.

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the second stage cyclone chambersdisclosed herein and that, in those embodiments, the second stagecyclone chambers may be of various constructions and that in thoseembodiments any second stage cyclone chamber known in the art may beused.

Dirt Collection Region for Second Stage Cyclones Positioned above andVverlying the First Stage Cyclone

The following is a description of the positioning of the dirt collectionregion for second stage cyclones that may be used by itself in anysurface cleaning apparatus or in any combination or sub-combination withany other feature or features disclosed herein including the sizing of asecond stage cyclone compared to a first stage cyclone, a dual openinglatching mechanism and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In accordance with one feature, at least a portion of, and preferablymost or substantially all of a second stage dirt collection region maybe positioned longitudinally above and overlying the first stage cyclonechamber. In such an embodiment, this preferred location for the secondstage dirt collection region may facilitate a more compact design of thecyclone assembly 100.

Referring to FIG. 11, a first stage dirt collection chamber 119 is incommunication with dirt outlet 118 to collect the dirt and debris as itexits first stage cyclone chamber 110. Dirt collection chamber 119 maybe of any suitable configuration. Referring to FIGS. 5 and 13, in theillustrated example, the dirt collection chamber 119 is bounded by outersidewall 108, first stage cyclone side wall 111, lower end wall 130, andintermediate wall 140.

As shown in FIGS. 9 and 10, in use air enters the first stage cyclonechamber 110 via air inlet 112 and exits the chamber 110 via air outlet114, while separated dirt and debris exits the cyclone chamber 110 viadirt outlet 118, where it collects in the first stage dirt collectionchamber 119.

To help facilitate emptying the dirt collection chamber 119, at leastone of or both of the end walls 130, 140 may be openable. Preferably,end wall 130 is moveable between a closed position (FIG. 13 and FIG. 7)and an open position (FIG. 8). When the end wall 130 is in the openposition, the first stage dirt collection chamber 119 and the manifold117 may be emptied concurrently. In addition, the second cyclonechambers are also opened so that the second cyclone chambers may also beconcurrently openable. Optionally, it will be appreciated that thesecond stage cyclone chambers need not be opened, e.g., if the lowerends of the second stage cyclone chambers are not moveable with end wall130. Accordingly, the lower end walls of the dirt collection chamber 119and/or the cyclone chamber 110 and/or the second stage cyclone chambers120 need not be integral with each other, and the dirt collectionchamber 119 and/or the cyclone chamber 110 and/or the second stagecyclone chambers 120 may be openable independently or in asub-combination, e.g., the dirt collection chamber 119 and the cyclonechamber 110 may be openable independently of the second stage cyclonechambers 120 or the dirt collection chamber 119 and the second stagecyclone chambers 120 may be openable independently of the cyclonechamber 110.

End wall 130 is preferably configured so that when it is in the closedposition, the upper surface 132 cooperatively engages a lower surface ofone or more of the sidewalls 108, 111, and 121 a-f. For example, asshown in FIGS. 8 and 15, the upper surface 132 may have one or morechannels or grooves 138 configured to receive the ends of sidewalls 108,111, and 121 a-f when the end wall 130 is in the closed position.Optionally, one or more sealing or gasketing elements may be providedbetween groove(s) 138 and the sidewall ends. Alternatively, the uppersurface 132 may be relatively planar, and configured to abut thesidewalls 108, 111, and 121 a-f, with or without gasketing elements.

Referring to FIG. 5, in the illustrated example, intermediate wall 140acts as an upper end wall for both dirt collection chamber 119 and firststage cyclone chamber 110. Wall 140 is moveable between a closedposition (FIG. 13) and an open position (FIG. 5). When the intermediatewall 140 is in the open position, the first stage cyclone chamber 110,the first stage dirt collection chamber 119, and the second stagecyclone chambers 120 a-f can be emptied concurrently. Alternatively, theupper end walls of the dirt collection chamber 119 and/or the cyclonechamber 110 and/or the second stage cyclone chambers 120 need not beintegral with each other, and the dirt collection chamber 119 and/or thecyclone chamber 110 and/or the second stage cyclone chambers 120 may beopenable independently or in a sub-combination, e.g., the dirtcollection chamber 119 and the cyclone chamber 110 may be openableindependently of the second stage cyclone chambers 120 or the dirtcollection chamber 119 and the second stage cyclone chambers 120 may beopenable independently of the cyclone chamber 110.

Wall 140 is preferably configured so that when it is in the closedposition, the lower surface 144 cooperatively engages an upper surfaceof one or more of the sidewalls 108, 111, and 121 a-f. For example, asshown in FIGS. 5 and 6, the lower surface 144 may have one or morechannels or grooves 148 configured to receive the ends of sidewalls 108,111, and 121 a-f when the wall 140 is in the closed position.Optionally, one or more sealing or gasketing elements may be providedbetween groove(s) 148 and the sidewall ends. Alternatively, the lowersurface 144 may be relatively planar, and configured to abut thesidewalls 108, 111, and 121 a-f, with or without gasketing elements.

As exemplified in FIGS. 4 and 11, a second stage dirt collection chamber129 may be associated with each second stage cyclone chamber 120. Asillustrated, each second stage dirt collection chamber 129 a-f is incommunication with a dirt outlet 128 a-f of its respective cyclonechamber 120 a-f to collect the dirt and debris as it exits that secondstage cyclone chamber. Dirt collection chambers 129 a-f may be of anysuitable configuration. Referring to FIGS. 4 and 13, in the illustratedexample, each dirt collection chamber 129 is bounded an upper sidewallextension 141, intermediate wall 140, upper end wall 150, and one ormore interior divider walls 145.

Alternately, two or more second stage cyclone chambers 120 may beassociated with a single second stage dirt collection chamber.Accordingly, for example, a single second stage dirt collection chambermay be provided. Collectively, the second stage dirt collectionchamber(s) may be referred to generally as a second stage dirtcollection region. Accordingly, while in the illustrated example eachsecond stage cyclone chamber 120 a-f has its own associated second stagedirt collection chamber 129 a-f, this need not be the case. For example,fewer or no interior divider walls 145 may be provided, resulting in twoor more second stage dirt outlets being in communication with a sharedsecond stage dirt collection chamber.

As shown in FIGS. 9 and 10, in use air enters each second stage cyclonechamber 120 a-f via an air inlet 122 a-f and exits each chamber 120 a-fvia an air outlet 124 a-f, while separated dirt and debris exits eachcyclone chamber 120 a-f via a dirt outlet 128 a-f, where it collects inthe second stage dirt collection region.

To help facilitate emptying the dirt collection chambers 129 a-f, endwall 150 may be openable. Preferably, end wall 150 is moveable between aclosed position (FIG. 13 and FIG. 5) and an open position (FIG. 4). Whenthe end wall 150 is in the open position, the second stage dirtcollection chambers 129 a-f can be emptied concurrently.

Notably, in the illustrated configuration, when the end wall 150 is in aclosed position and the intermediate wall 140 is in the open position,as shown in FIG. 5, the first stage cyclone chamber 110, the first stagedirt collection chamber 119, and the second stage cyclone chambers 120a-f may be emptied concurrently, while the second stage dirt collectionchambers 129 a-f remain closed.

It will be appreciated that the second stage dirt collection region maybe opened regardless of the position of the upper end 104 (i.e., whetherintermediate wall 140 is open or closed).

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the dirt collection chambers disclosedherein and that, in those embodiments, the dirt collection chambers maybe of various constructions and that in those embodiments any dirtcollection chamber known in the art may be used.

Cyclone Assembly with Openable Ends

The following is a description of a cyclone assembly that may be used byitself in any surface cleaning apparatus or in any combination orsub-combination with any other feature or features disclosed hereinincluding the sizing of a second stage cyclone compared to a first stagecyclone, and the connection of the second stage cyclone chamber airoutlets with an upstream chamber of a pre-motor filter

FIGS. 23-29 exemplify another embodiment of a cyclone assembly, referredto generally as 100′. Cyclone assembly 100′ may be used as an airtreatment member to remove particulate matter (e.g. dirt, dust) from anair flow. Preferably, the cyclone assembly is removable from the surfacecleaning apparatus. Providing a detachable cyclone assembly 100′ mayallow a user to carry the cyclone assembly 100′ to a garbage can foremptying, without needing to carry or move the rest of the surfacecleaning apparatus 10. Preferably, the cyclone assembly is removable asa closed module, which may help prevent dirt and debris from spillingout of the cyclone assembly 100′ during transport for emptying.

As exemplified in FIG. 23, the cyclone assembly 100 has a lower end 102,an upper end 104, and an outer sidewall 108. Preferably, an assemblyhandle 106 is provided at the upper end 104. The assembly handle 106 mayfacilitate carrying of the cyclone assembly when it is detached from thesurface cleaning apparatus 10.

Referring to FIGS. 23-29, cyclone assembly 100 includes a first cycloniccleaning stage and a second cyclonic cleaning stage located downstreamof the first cyclonic cleaning stage. The first cyclonic cleaning stageincludes a first stage cyclone chamber 110′ that extends along a cycloneaxis 115′ and includes a sidewall 111′, which may be generallycylindrical, extending between a lower end wall 113′ and an upper endwall 150′. In the illustrated embodiment, the first stage cyclonechamber 110′ is arranged in a generally vertical, inverted cycloneorientation. Alternatively, the first stage cyclone chamber may beprovided in another orientation, for example as a horizontal or inclinedcyclone and may be of any cyclone configuration. Alternately, or inaddition, the first cyclonic cleaning stage may comprise a plurality ofcyclone chambers.

In the illustrated embodiment, the first stage cyclone chamber 110′includes a first stage cyclone air inlet 112′ and a first stage cycloneair outlet 114′. First stage cyclone chamber 110′ also includes at leastone dirt outlet 118′, through which dirt and debris that is separatedfrom the air flow can exit the cyclone chamber 110′. While it ispreferred that most or all of the dirt exit the first stage cyclonechamber via the dirt outlet 118′, some dirt may settle on the bottom endwall 113′ of the cyclone chamber 110′ and/or may be entrained in the airexiting the first stage cyclone chamber via the air outlet 114′.

In the illustrated example, the first stage cyclone dirt outlet 118′ isin the form of a slot bounded by the cyclone side wall 111′ and theupper cyclone end wall 150′, and is located toward the upper end of thecyclone chamber 110′. Alternatively, the dirt outlet may be of any othersuitable configuration, including, for example as an annular gap betweenthe sidewall and an end wall of the cyclone chamber or a plate or othersuitable member extending towards or into the open upper end of thecyclone chamber 110′.

Preferably, the first stage cyclone air inlet 112′ is located toward theend of the cyclone chamber 110′ spaced from the end with the dirt outlet(the lower end in the illustrated example) and may be positionedadjacent the corresponding cyclone chamber end wall 113′. Preferably,the air inlet 112′ is positioned so that air flowing through the inletand into the first stage cyclone chamber is travelling generallytangentially relative to, and preferably adjacent, the sidewall 111′ ofthe cyclone chamber 110′.

The cross-sectional shape of the air inlet 112′ may be any suitableshape. In the illustrated example of FIG. 24, the air inlet has across-sectional shape that is generally rectangular (e.g., it hasrounded corners and can be referred to as a rounded rectangle). Thecross-sectional area of the air inlet 112′ may be referred to as thecross-sectional area or flow area of the first stage cyclone air inlet112′. Alternatively, instead of being a rounded rectangle, thecross-sectional shape of the air inlet may be another shape, including,for example, round, oval, square and rectangular.

Referring to FIG. 25, the first stage cyclone chamber 110′ has a heightin the longitudinal direction (i.e. parallel to cyclone axis 115′),being the distance between the lower end wall 113′ and upper end wall150′. The height of the first stage cyclone chamber 110′ is preferablyselected such that air entering the cyclone chamber via inlet 112′ isexpected to rotate approximately 3 to 6 times, 3 to 5 times, 2 to 4times or three-and-a-half times in the first stage cyclone chamber priorto exiting the cyclone chamber via outlet 114′.

In general, it may be assumed that the airflow against the cyclonechamber sidewall as it progresses around the cyclone chamber maintains adegree of cohesion, and that during each revolution within a cyclonechamber, an air stream moves in the longitudinal direction towards anend of the cyclone chamber by a distance approximately equal to theheight of the cyclone chamber air inlet. For example, in a cyclonechamber that has a longitudinal height that is five times greater thanthe longitudinal height of its air inlet, the resulting cyclone may beexpected to rotate about five times as it travels from the end of thecyclone chamber that has the air inlet to the opposite end of thecyclone chamber.

Thus, in order to promote the formation of a cyclone that is expected torotate about three-and-a-half times in the first stage cyclone chamber110′, the height of the first stage cyclone chamber 110′ may be between3 and 4 times the height of the first stage cyclone air inlet 112′.

Air may exit the first stage cyclone chamber 110′ via the first stageair outlet 114′. Preferably, the cyclone air outlet is positioned in oneof the cyclone chamber end walls and, in the example illustrated, ispositioned in the same end as the air inlet 112′ and air inlet 112′ maybe positioned adjacent or at the end wall 113′. As exemplified, the airoutlet 114′ may be generally circular in cross-sectional shape.Preferably, the cross-sectional or flow area of the first stage cycloneair outlet 114′ is generally equal to the flow area of the first stagecyclone air inlet 112′. In the illustrated example, the cyclone airoutlet 114′ comprises a vortex finder 116′.

Air exiting the first stage air outlet 114′ may be directed into achamber or manifold 117′. From there, the air is directed into thesecond cyclonic cleaning stage through one or more air flow passages.The second cyclonic cleaning stage includes a plurality of second stagecyclone chambers 120′ arranged in parallel. In the illustratedembodiment, two second stage cyclone chambers are shown, referred to as120 a′ and 120 b′, respectively.

In the illustrated embodiment, each second stage cyclone chamber 120′ isarranged in a generally vertical, inverted cyclone orientation.Alternatively, the second stage cyclone chambers can be provided inanother orientation, for example as horizontal or inclined cyclones andmay be of any cyclone configuration.

In the illustrated embodiment, each second stage cyclone chamber extendsalong a respective cyclone axis 125′ (see e.g. FIG. 25) and extendsbetween a lower end wall or bottom 131 a′, 131 b′ and an upper end wall150′. In the illustrated embodiment, each second stage cyclone chamberis bounded by a sidewall 121 a′, 121 b′.

In the illustrated embodiment, each second stage cyclone chamber 120′includes an airflow passage 123′ extending from manifold 117′ to asecond stage cyclone air inlet 122′ and a second stage cyclone airoutlet 124′. Each second stage cyclone chamber 120′ also includes atleast one dirt outlet 128′, through which dirt and debris that isseparated from the air flow can exit the cyclone chamber 120′. While itis preferred that most or all of the dirt entrained in the air exitingthe first cyclonic cleaning stage exits the second stage cyclonechambers via the dirt outlets 128′, some dirt may settle on the bottomend wall 131′ of the cyclone chambers 120′ and/or may be entrained inthe air exiting the second stage cyclone chambers via the air outlets124′.

In some embodiments, all or substantially all of the dirt entrained inthe air exiting the first cyclonic cleaning stage may be removed fromthe airflow by the second cyclonic cleaning stage. This may, forexample, obviate the need to provide a pre-motor filter in the surfacecleaning apparatus 10.

In the illustrated example, each second stage cyclone dirt outlet 128′is in the form of a slot bounded by the cyclone side wall 121′ and theupper cyclone end wall 150′, and is located toward the upper end of thecyclone chamber 120′. Alternatively, the dirt outlet may be of any othersuitable configuration, including, for example, as an annular gapbetween the sidewall and an end wall of the cyclone chamber or a plateor other suitable member extending towards or into the open upper end ofthe cyclone chamber 120′.

Preferably, each second stage cyclone air inlet 122′ is located towardthe end of the cyclone chamber 120′ spaced from the end with the dirtoutlet (the lower end in the illustrated example) and may be positionedadjacent the corresponding cyclone chamber end wall 131′. Alternatively,the cyclone air inlet 122′ may be provided at another location withinthe second stage cyclone chamber 120′. Preferably, each air inlet 122′is positioned so that air flowing through the inlet and into a secondstage cyclone chamber is travelling generally tangentially relative to,and preferably adjacent, the sidewall 121′ of that cyclone chamber 120′.

The cross-sectional shape of the air inlet 122′ may be any suitableshape. In the illustrated example each air inlet has a cross-sectionalshape that is generally rectangular, having a height in the longitudinaldirection (i.e. parallel to cyclone axis 125′) and a width in atransverse direction. The total cross-sectional area of the second stageair inlets (i.e. the sum of the cross-sectional areas of each inlet 122a′, 122 b′) may be referred to as the total cross-sectional area ortotal flow area of the second cyclonic cleaning stage.

Referring to FIGS. 25 and 28, each second stage cyclone chamber 120′ hasa height in the longitudinal direction (i.e. parallel to cyclone axis125′). The height of each second stage cyclone chamber 120′ ispreferably selected such that air entering the cyclone chambers viainlets 122′ is expected to rotate approximately 3 to 6 times, 3 to 5times, 2 to 4 times or three-and-a-half times in each second stagecyclone chamber prior to exiting the cyclone chamber via outlet 124′.For example, the height of a second stage cyclone chamber 120′ may bebetween 3 and 4 times the height of a second stage cyclone air inlet122′.

Air may exit each second stage cyclone chambers 120′ via a second stageair outlet 124′ provided for each cyclone chamber 120′. In theillustrated example, corresponding ports 127 a′, 127 b′ are provided inend wall 130′ to allow air to exit the cyclone assembly 100′.Preferably, the cyclone air outlets 124 a-b′ are positioned in one ofthe end walls of each cyclone chamber 120′ and, in the exampleillustrated, are positioned in the same ends as the air inlets 122 a-b′.As exemplified, the air outlets 124 a-b′ may be generally circular incross-sectional shape. Preferably, the cross-sectional or flow area ofeach second stage cyclone air outlet 124′ is generally equal to the flowarea of the second stage cyclone air inlet 122′ for its respectivecyclone chamber. In the illustrated example, each cyclone air outlet124′ comprises a vortex finder 126′.

Referring to FIGS. 25 and 26, a first stage dirt collection chamber 119′is in communication with dirt outlet 118′ to collect the dirt and debrisas it exits first stage cyclone chamber 110′. Dirt collection chamber119′ may be of any suitable configuration. In the illustrated example,the dirt collection chamber 119′ is bounded by outer sidewall 108′,first stage cyclone side wall 111′, lower end wall 130′, and upper endwall 150′.

In use, air enters the first stage cyclone chamber 110′ via air inlet112′ and exits the chamber 110′ via air outlet 114′, while separateddirt and debris exits the cyclone chamber 110′ via dirt outlet 118′,where it collects in the first stage dirt collection chamber 119′.

To help facilitate emptying the dirt collection chamber 119′, at leastone of or both of the end walls 130′, 150′ may be openable. Preferably,end wall 130′ is moveable between a closed position (e.g. FIG. 27) andan open position (e.g. FIG. 28). When the end wall 130′ is in the openposition, the first stage dirt collection chamber 119′ and the manifold117′ may be emptied concurrently. In addition, the air flow passages123′ from manifold 117′ to the second cyclone air inlets 122′ are alsoopened so that the air flow passages 123′ may also be concurrentlyopenable. Optionally, it will be appreciated that the air flow passagesto the second stage cyclone chambers need not be opened, e.g., if thelower ends of the air flow passages 123′ are not moveable with end wall130′.

Also, when the end wall 130′ is in the open position, in the illustratedexample the second cyclone chambers are not opened. Optionally, it willbe appreciated that the second stage cyclone chambers may be openedconcurrently with one or more of the first stage dirt collection chamber119′, the air flow passages 123′ and manifold 117′, e.g., if the lowerends of the second stage cyclone chambers are moveable with end wall130′ (e.g., the lower ends of the second stage cyclone chambers 119′,the lower end of the air flow passages 123′ and the lower end of themanifold 117′ are part of the end wall 130′). Accordingly, the lower endwalls of the dirt collection chamber 119′, the air flow passages 123′,the manifold 117′ and the second stage cyclone chambers 120 a′, 120 b′may be integral with each other. Alternately, the lower end walls of thedirt collection chamber 119′ and/or the cyclone chamber 110′ and/or thesecond stage cyclone chambers 120′ and/or the air flow passages 123′and/or the manifold 117′ need not be integral with each other, and thedirt collection chamber 119′ and/or the cyclone chamber 110′ and/or thesecond stage cyclone chambers 120′ and/or the air flow passages 123′and/or the manifold 117′ may be openable independently or in asub-combination, e.g., the dirt collection chamber 119′ may be openableindependently of the second stage cyclone chambers 120′.

End wall 130′ is preferably configured so that when it is in the closedposition, the upper surface 132′ cooperatively engages a lower surfaceof one or more of the sidewalls 108′, and 121 a′, 121 b′. For example,as shown in FIG. 28, the upper surface 132′ may have one or morechannels or grooves 138′ configured to receive the ends of sidewalls108′, and 121 a′, 121 b′ when the end wall 130′ is in the closedposition. Optionally, one or more sealing or gasketing elements may beprovided between groove(s) 138′ and the sidewall ends. Alternatively,the upper surface 132′ may be relatively planar, and configured to abutthe sidewalls 108′, and 121 a′, 121 b′, with or without gasketingelements.

As exemplified in FIGS. 25 and 26, a second stage dirt collectionchamber 129′ may be associated with each second stage cyclone chamber120′. As illustrated, each second stage dirt collection chamber 129 a′,129 b′ is in communication with a dirt outlet 128 a′, 128 b′ of itsrespective cyclone chamber 120 a′, 120 b′ to collect the dirt and debrisas it exits that second stage cyclone chamber. Dirt collection chambers129 a′, 129 b′ may be of any suitable configuration. In the illustratedexample, dirt collection chamber 129 a′ is bounded by an upper portionof sidewall 121 a′, an intermediate wall 140 a′, upper end wall 150′, aninterior divider wall 145 a′, and sidewall 111′ of the cyclone chamber110′. Also, in the illustrated example, dirt collection chamber 129 b′is bounded by an upper portion of sidewall 121 b′, an intermediate wall140 b′, upper end wall 150′, an interior divider wall 145 b′, andsidewall 108′.

Alternately, two or more second stage cyclone chambers 120′ may beassociated with a single second stage dirt collection chamber.Accordingly, for example, a single second stage dirt collection chambermay be provided. Collectively, the second stage dirt collectionchamber(s) may be referred to generally as a second stage dirtcollection region. Accordingly, while in the illustrated example eachsecond stage cyclone chamber 120 a′, 120 b′ has its own associatedsecond stage dirt collection chamber 129 a′, 120 b′, this need not bethe case. For example, dirt outlet 128 b′ may be provided such that itfaces towards dirt collection chamber 129 a′ (e.g. on the opposite sideof second stage cyclone chamber 120 b′ as shown), resulting in two ormore second stage dirt outlets being in communication with a sharedsecond stage dirt collection chamber.

In use, air enters each second stage cyclone chamber 120 a′, 120 b′ viaan air inlet 122 a′, 122 b′ and exits each chamber 120 a′, 120 b′ via anair outlet 124 a′, 124 b′, while separated dirt and debris exits eachcyclone chamber 120 a′, 120 b′ via a dirt outlet 128 a′, 128 b′, whereit collects in the second stage dirt collection region.

It will be appreciated that the lower wall of one or more second stagedirt collection chamber 129 a′, 120 b′ may be moveable with, and may beintergrally formed with, end wall 130′ such that the second stage dirtcollection chambers may be openable with one or more of the dirtcollection chamber 119′, the cyclone chamber 110′, the second stagecyclone chambers 120′ and the air flow passages 123′ and/or the manifold117′.

Referring to FIG. 25, in the illustrated example, upper end wall 150′acts as an upper end wall for each of dirt collection chamber 119′,first stage cyclone chamber 110′, second stage cyclones 120 a′, 120 b′,and second stage dirt collection chambers 129 a′, 129 b′. Wall 150′ ismoveable between a closed position (e.g. FIG. 23) and an open position(e.g. FIG. 25). When the upper end wall 150′ is in the open position,the first stage cyclone chamber 110′, the first stage dirt collectionchamber 119′, the second stage cyclone chambers 120 a′, 120 b′, and thesecond stage dirt collection chambers 129 a′, 129 b′ can be emptiedconcurrently.

Wall 150′ is preferably configured so that when it is in the closedposition, the lower surface 154′ cooperatively engages an upper surfaceof one or more of the sidewalls 108′, 111′, and 121 a′, 121 b′. Forexample, as shown in FIG. 25, the lower surface 154′ may have one ormore channels or grooves 158′ configured to receive the ends ofsidewalls 108′, 111′, and 121 a′, 121 b′ when the wall 150′ is in theclosed position. Optionally, one or more sealing or gasketing elementsmay be provided between groove(s) 158′ and the sidewall ends.Alternatively, the lower surface 154′ may be relatively planar, andconfigured to abut the sidewalls 108′, 111′, and 121 a′, 121 b′, with orwithout gasketing elements.

As discussed previously, in the illustrated example dirt collectionchamber 129 a′ is bounded by an upper portion of sidewall 121 a′, anintermediate wall 140 a′, upper end wall 150′, an interior divider wall145 a′, and sidewall 111′ of the cyclone chamber 110′, and dirtcollection chamber 129 b′ is bounded by an upper portion of sidewall 121b′, an intermediate wall 140 b′, upper end wall 150′, an interiordivider wall 145 b′, and sidewall 108′. Alternatively, one or both ofintermediate walls 140 a′, 140 b′ may not be provided. For example, ifintermediate wall 140 a′ is not provided, dirt collection chamber 129 a′may be bounded by sidewall 121 a′, upper end wall 150′, an interiordivider wall 145 a′, sidewall 111′ of the cyclone chamber 110′, andlower end wall 130′. Similarly, if intermediate wall 140 b′ is notprovided, dirt collection chamber 129 b′ may be bounded by sidewall 121b′, upper end wall 150′, interior divider wall 145 b′, sidewall 108′,and lower end wall 130′.

An advantage of a configuration in which one or both of intermediatewalls 140 a′, 140 b′ are not provided is that when the end wall 130′ isin the open position, one or both of second stage dirt collectionchambers 129 a′, 129 b′ may be emptied concurrently with the first stagedirt collection chamber 119′, the manifold 117′, and/or the air flowpassages 123′ from manifold 117′ to the second cyclone air inlets 122a′, 122 b′. Alternatively, instead of not providing intermediate walls140 a′, 140 b′, one or more holes, slots or other apertures may beprovided in one or both of intermediate walls 140 a′, 140 b′ to allowsome or all of the dirt collected in dirt collection chambers 129 a′,129 b′ to be emptied when the end wall 130′ is in the open position.

Latching Mechanism

The following is a description of a dual opening latching mechanism thatmay be used by itself in any surface cleaning apparatus or in anycombination or sub-combination with any other feature or featuresdisclosed herein including the sizing of a second stage cyclone comparedto a first stage cyclone, the positioning of a dirt collection regionfor second stage cyclones and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In accordance with this feature, a latching mechanism with amulti-position switch or release mechanism may be provided toselectively retain the intermediate wall 140 and/or the upper end wall150 in its respective closed position. An advantage of this design isthat it may prevent a user from inadvertently opening both theintermediate wall 140 and the upper end wall 150 at the same time.

As exemplified in FIGS. 16-22, a latching mechanism, referred togenerally as 200, is provided between the intermediate wall 140 and theupper end wall 150. Latching mechanism 200 includes an upper latch forselectively retaining upper end wall 150 in its closed position, and alower latch for selectively retaining intermediate end wall 140 in itsclosed position. A release switch 260 is provided for selectivelydisengaging the upper latch or the lower latch.

Release switch 260 is an actuator that is moveable in two differentdirections, (e.g., left and right). When the actuator is moved in afirst direction, a first locking member is moved to an unlocked positionwhile a second locking member is maintained in a locked position. Whenthe actuator is moved in a second direction, which may be an oppositedirection to the first direction, the second locking member is moved toan unlocked position while the first locking member is maintained in alocked position. It will be appreciated that the first and secondlocking members may be separate elements or they may be opposite ends ofa single linkage.

As exemplified in FIGS. 17, 19, and 22, the upper latch includes agenerally U-shaped latching bar 220 that is pivotally coupled to a shaft210. Shaft 210 is parallel to both the intermediate wall 140 and theupper end wall 150. The upper end of the latching bar 220 has adownwardly facing surface 224 that is configured to engage with a lip orflange 225 extending from the upper end wall 150 to cooperatively retainthe end wall 150 in its closed position. When the latching bar 220 is ina locked position (as shown in FIGS. 17 and 22) and upper end wall 150in its closed position, downwardly facing surface 224 overlies flange225, thereby retaining upper end wall 150 in its closed position.Preferably, latching bar 220 is biased towards its locked position, forexample, using a spring or other biasing member(s) (not shown).

The upper end of the latching bar 220 also has an upwardly facing angledor beveled surface 222 that is configured to pivot the latching bar 220away from the locked position when engaged by an angled or beveledsurface 223 of flange 225, thereby allowing the upper latch to beengaged by bringing the end wall 150 to its closed position.

Latching bar 220 also has a flange or projection 226 that extendsgenerally forwardly. As shown in FIG. 17, projection 226 is angled orsloped such that one lateral end of the projection 226 extends furtherforward than the opposite lateral end.

As exemplified in FIGS. 19, 21, and 22, the lower latch includes alatching bar 240 that is also pivotally coupled to shaft 210. The lowerend of latching bar 240 has an upwardly facing surface 244 that isconfigured to engage with a lip or flange 245 extending from the outersidewall 108 to cooperatively retain the intermediate wall 140 in itsclosed position. When the latching bar 240 is in a locked position (asshown in FIGS. 19 and 21) and intermediate wall 140 in its closedposition, upwardly facing surface 244 overlies flange 245, therebyretaining intermediate wall 140 in its closed position. Preferably,latching bar 240 is biased towards its locked position, for example,using a spring or other biasing member(s) (not shown).

The lower end of the latching bar 240 also has a downwardly facingangled or beveled surface 242 that is configured to pivot the latchingbar 240 away from its locked position when engaged by an angled orbeveled surface 243 of flange 245, thereby allowing the lower latch tobe engaged by bringing the intermediate wall 140 to its closed position.

Latching bar 240 also has a flange or projection 246 that extendsgenerally forwardly. As exemplified in FIGS. 17 and 21, projection 246is angled or sloped such that one lateral end of the projection 246extends further forward than the opposite lateral end. Notably,projections 246 and 226 are angled in opposite directions. Thisarrangement facilitates the selective unlatching of either the upper orlower latch using a single multi-position switch or release mechanism.

As exemplified in FIG. 16, the release switch 260 for latching mechanism200 is rotatably or pivotally coupled to a shaft 270. Shaft 270 isgenerally perpendicular to both the intermediate wall 140 and the upperend wall 150. Release switch 260 also includes an outwardly facingprojection or tab 262 to facilitate a user's rotation of switch 260about shaft 270. Release switch 260 also includes an inwardly facingflange or projection 264 that is configured to engage the projections226, 246 of the upper and lower latching bars 220, 240, respectively.

As exemplified in FIGS. 16, 17 and 21, the release switch 260 is shownin a neutral position. In this position, inwardly facing projection 264is not in contact with either projection 226 or projection 246. As therelease switch 260 is pivoted towards the position shown in FIG. 18,projection 264 is brought into abutment with projection 226 of the upperlatching mechanism. Further pivoting of release switch 260 forces theupper latching bar 220 away from its locked position, and therebyunlatching the upper latch (as shown in FIG. 19) and permitting theupper end wall 150 to be moved to an open position.

Alternatively, if the release switch 260 is pivoted towards the positionshown in FIG. 20, projection 264 is brought into abutment withprojection 246 of the lower latching mechanism. Further pivoting ofrelease switch 260 forces the lower latching bar 240 away from itslocked position, and thereby unlatching the lower latch (as shown inFIG. 22) and permitting the intermediate wall 140 to be moved to an openposition.

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the latching mechanisms disclosed hereinand that, in those embodiments, mechanisms for retaining theintermediate and upper walls in their closed positions may be of variousconstructions and that in those embodiments any latching or retainingmechanism known in the art may be used.

Air Outlets for Second Stage Cyclones Provided in a Wall of CommonManifold, which may be a Pre-Motor Filter Chamber

The following is a description of the connection of the second stagecyclone chamber air outlets with an upstream chamber of a pre-motorfilter for the second cyclonic cleaning that may be used by itself inany surface cleaning apparatus or in any combination or sub-combinationwith any other feature or features disclosed herein including the sizingof a second stage cyclone compared to a first stage cyclone, thepositioning of a dirt collection region for second stage cyclones and adual opening latching mechanism.

In accordance with this feature, the air outlets of a plurality ofcyclone chambers that are connected in parallel may be connecteddirectly to an upstream pre-motor filter chamber or manifold.Accordingly, some or all of the air outlets may extend to openingprovided in the manifold. Accordingly, a manifold for the air outlets,which is upstream from the pre-motor filter chamber, is not provided.

Optionally, the upstream pre-motor filter chamber or manifold may bepositioned in facing relationship with the air outlets of a plurality ofcyclone chambers that are connected in parallel. Accordingly, theupstream face of the pre-motor filter may be positioned generallytransverse to the axis of the cyclone air outlets, and the axis of thecyclone air outlets may be generally parallel to the cyclone of whichthey are the air exits. Therefore, for example, the manifold may bepositioned below a second cyclonic cleaning stage and each of the secondstage cyclone air outlets may have an outlet end in a wall of thechamber or manifold. An advantage of this design is that fewer conduitwalls and/or ducting may be required to direct airflow from the secondcyclonic cleaning stage towards the suction unit, which may simplify thedesign and/or construction of the cyclone assembly and/or surfacecleaning apparatus, and/or may reduce backpressure through the surfacecleaning apparatus.

As exemplified in FIGS. 9-11, air exiting the second stage air outlets124 a-f is directed into a chamber or header or manifold 27 bounded bythe lower surface 134 of the lower end wall 130 of cyclone assembly 100and the upper end of the suction unit 20. From there, the air isdirected by the suction motor through the suction unit 20 andsubsequently exhausted out through the clean air outlet 18.

In alternative embodiments, cyclone assembly 100 may include one or moreadditional manifolds downstream of the second stage air outlets 124 a-fso that cyclone assembly 100 has a single assembly air outlet or fewerair outlets than there are second stage cyclone chambers.

As exemplified, the chamber or header or manifold is a pre-motor filterchamber that houses a pre-motor filter. In such a construction, thepre-motor filter chamber may be opened when the cyclone bin assembly isremoved. For example, the cyclone bin assembly may form part of thepre-motor filter chamber (e.g., an upstream wall of the pre-motor filterchamber). An advantage of this design is that the pre-motor filterchamber is opened when the cyclone bin assembly is removed. Accordingly,when a user removes the cyclone bin assembly (e.g. to empty the dirtcollection chamber(s)), the user may also inspect the condition of thepre-motor filter. The pre-motor filter may be any suitable type ofporous filter media, such as a foam filter and/or a felt filter, or anyother suitable pre-motor porous filter media(s) known in the art.Preferably, the pre-motor filter is removable to allow a user to cleanand/or replace the filter when it is dirty.

Typically, a pre-motor filter is provided to prevent particulate matterthat is not removed from the airstream by the cyclonic cleaning stagesfrom being drawn into the suction motor. Otherwise, this unremovedparticulate matter may cause damage to (or otherwise impair) the suctionmotor.

While the use of a pre-motor filter may be effective at protecting thesuction motor, there may be one or more disadvantages. For example, thepre-motor filter may become clogged with particulate matter, requiring auser to clean and/or replace the filter, a task a user may regard asundesirable.

As used herein, the wording “and/or” is intended to represent aninclusive—or. That is, “X and/or Y” is intended to mean X or Y or both,for example. As a further example, “X, Y, and/or Z” is intended to meanX or Y or Z or any combination thereof.

While the above description describes features of example embodiments,it will be appreciated that some features and/or functions of thedescribed embodiments are susceptible to modification without departingfrom the spirit and principles of operation of the describedembodiments. For example, the various characteristics which aredescribed by means of the represented embodiments or examples may beselectively combined with each other. Accordingly, what has beendescribed above is intended to be illustrative of the claimed conceptand non-limiting. It will be understood by persons skilled in the artthat other variants and modifications may be made without departing fromthe scope of the invention as defined in the claims appended hereto. Thescope of the claims should not be limited by the preferred embodimentsand examples, but should be given the broadest interpretation consistentwith the description as a whole.

1. A cyclone assembly for a surface cleaning apparatus comprising: (a)an openable lower end; (b) a first cyclonic cleaning stage comprising atleast one first stage inverted cyclone having a first stage cyclonechamber and an upper end; (c) a second cyclonic cleaning stagedownstream from the first cyclonic cleaning stage and comprising aplurality of inverted second stage cyclones in parallel, each of theplurality of second stage cyclones having a second stage cyclonechamber; and, (d) an air flow passage from the first cyclonic cleaningstage to the second cyclonic cleaning stage, wherein the lower end ismoveable between a closed position and an open position in which atleast a portion of the air flow passage is opened.
 2. The cycloneassembly of claim 1 wherein the second cyclonic cleaning stage comprisesat least one second stage dirt collection region that is exterior to thesecond stage cyclone chambers and the at least one second stage dirtcollection region is opened when the lower end is moved to the openposition.
 3. The cyclone assembly of claim 2 wherein the lower endcomprises a single pivotally openable panel.
 4. The cyclone assembly ofclaim 2 wherein the lower end comprises at least one outlet port for thesecond cyclonic cleaning stage.
 5. The cyclone assembly of claim 2further comprising an upper end that is moveable between a closedposition and an opening position in which the first and second cyclonechambers are opened.
 6. The cyclone assembly of claim 5 furthercomprising a first stage dirt collection region exterior to the firststage cyclone chamber and the first stage dirt collection region isopened when the an upper end is moved to the open position.
 7. Thecyclone assembly of claim 6 wherein the second cyclonic cleaning stagecomprises at least one second stage dirt collection region that isexterior to the second stage cyclone chambers and the at least onesecond stage dirt collection region is opened when the upper end ismoved to the open position.
 8. A cyclone assembly for a surface cleaningapparatus comprising: (a) an openable upper end and an openable lowerend; (b) a first cyclonic cleaning stage comprising at least one firststage inverted cyclone having a first stage cyclone chamber, an upperend and a dirt outlet at the upper end in communication with a firststage dirt collection region exterior to the first stage cyclonechamber; (c) a second cyclonic cleaning stage downstream from the firstcyclonic cleaning stage and comprising a plurality of inverted secondstage cyclones in parallel, each of the plurality of second stagecyclones having a second stage cyclone chamber, an upper end and a dirtoutlet at the upper end wherein the dirt outlets of the second stagecyclone chambers are in communication with at least one second stagedirt collection region exterior to the second stage cyclone chamberswherein the upper end is moveable between a closed position and anopening position in which the first and second cyclone chambers areopened, and wherein the lower end is moveable between a closed positionand an open position in which the first stage dirt collection region andthe at least one second stage dirt collection region are opened.
 9. Thecyclone assembly of claim 8 wherein the second stage comprises aplurality of second stage dirt collection regions and the plurality ofsecond stage dirt collection regions are opened when the lower end isopened.
 10. The cyclone assembly of claim 8 wherein the at least onesecond stage dirt collection region is opened when the upper end isopened.
 11. The cyclone assembly of claim 10 wherein the second stagecomprises a plurality of second stage dirt collection regions and theplurality of second stage dirt collection regions are opened when theupper end is opened.
 12. The cyclone assembly of claim 10 furthercomprising an air flow passage from the first cyclonic cleaning stage tothe second cyclonic cleaning stage, wherein at least a portion of theair flow passage is opened when the lower end is opened.
 13. The cycloneassembly of claim 8 wherein the lower end comprises at least one outletport for the second cyclonic cleaning stage.
 14. A cyclone assembly fora surface cleaning apparatus comprising: (a) an openable upper end andan openable lower end; (b) a first cyclonic cleaning stage comprising atleast one first stage inverted cyclone having an air inlet and an airoutlet at a lower end of a first stage cyclone chamber and a first stagedirt outlet provided in an upper portion of a first stage cyclonesidewall of the first stage cyclone chamber, the first stage dirt outletin communication with a first stage dirt collection region exterior tothe first stage cyclone chamber wherein the upper end abuts an upper endof the first stage cyclone sidewall when the upper end is in a closedposition; (c) a second cyclonic cleaning stage downstream from the firstcyclonic cleaning stage and comprising a plurality of inverted secondstage cyclones in parallel, each of the plurality of second stagecyclones having a cyclone chamber having an air inlet and an air outletat a lower end thereof and a second stage dirt outlet provided in anupper portion of a second stage cyclone sidewall of the second stagecyclone chamber, wherein the second stage dirt outlets are incommunication with at least one second stage dirt collection regionexterior to the second stage cyclone chambers wherein the upper endabuts an upper end of the second stage cyclone sidewalls when the upperend is in a closed position, wherein, when the upper end is in an openposition, the first and second stage cyclone chambers are opened. 15.The cyclone assembly of claim 14 wherein the second stage comprises aplurality of second stage dirt collection regions and the plurality ofsecond stage dirt collection regions are opened when the lower end isopened.
 16. The cyclone assembly of claim 15 wherein the lower endcomprises at least one outlet port for the second cyclonic cleaningstage.
 17. The cyclone assembly of claim 14 wherein the at least onesecond stage dirt collection region is opened when upper end is opened.18. The cyclone assembly of claim 17 wherein the second stage comprisesa plurality of second stage dirt collection regions and the plurality ofsecond stage dirt collection regions are opened when upper end isopened.
 19. The cyclone assembly of claim 17 further comprising an airflow passage from the first cyclonic cleaning stage to the secondcyclonic cleaning stage, wherein at least a portion of the air flowpassage is opened when the lower end is opened.
 20. The cyclone assemblyof claim 14 wherein the lower end comprises at least one outlet port forthe second cyclonic cleaning stage.